Epson RS4 SCARA Robots User manual

Rev.16 EM183R3631F

SCARA ROBOT

RS series

MANIPULATOR MANUAL

RS series Rev.16

RS Rev.16 i

SCARA ROBOT

RS series Manipulator Manual

Rev.16

ii RS Rev.16

FOREWORD

Thank you for purchasing our robot products.

This manual contains the information necessary for the correct use of the manipulator.

Please carefully read this manual and other related manuals before installing the robot

system.

Keep this manual handy for easy access at all times.

WARRANTY

The Manipulator and its optional parts are shipped to our customers only after being

subjected to the strictest quality controls, tests, and inspections to certify its compliance

with our high performance standards.

Product malfunctions resulting from normal handling or operation will be repaired free of

charge during the normal warranty period. (Please ask your Regional Sales Office for

warranty period information.)

However, customers will be charged for repairs in the following cases (even if they occur

during the warranty period):

1.

Damage or malfunction caused by improper use which is not described in the manual,

or

careless use.

2.

Malfunctions caused by customers’ unauthorized disassembly.

3.

Damage due to improper adjustments or unauthorized

repair attempts.

4.

Damage caused by natural disasters such as earthquake, flood, etc.

Warnings, Cautions, Usage:

1.

If the

Manipulator

or associated equipment is used outside of the usage conditions and

product

specifications described in the manuals, this warranty is void.

2.

If you do not follow the WARNINGS and CAUTIONS in this manual, we cannot be

responsible for any malfunction or accident, even if the result is injury or death.

3.

We cannot foresee all possible dangers and consequences. Therefore, this manual

cannot warn the user of all possible hazards.

RS Rev.16 iii

TRADEMARKS

Microsoft, Windows, and Windows logo are either registered trademarks or trademarks of

Microsoft Corporation in the United States and/or other countries. Other brand and

product names are trademarks or registered trademarks of the respective holders.

NOTICE

No part of this manual may be copied or reproduced without authorization.

The contents of this manual are subject to change without notice.

Please notify us if you should find any errors in this manual or if you have any comments

regarding its contents.

MANUFACTURER

iv RS Rev.16

Regarding battery disposal

The crossed out wheeled bin label that can be found on your product indicates that this

product and incorporated batteries should not be disposed of via the normal household

waste stream. To prevent possible harm to the environment or human health please

separate this product and its batteries from other waste streams to ensure that it can be

recycled in an environmentally sound manner. For more details on available collection

facilities please contact your local government office or the retailer where you purchased

this product. Use of the chemical symbols Pb, Cd or Hg indicates if these metals are used

in the battery.

This information only applies to customers in the European Union, according to

DIRECTIVE 2006/66/EC OF THE EUROPEAN PARLIAMENT AND OF THE

COUNCIL OF 6 September 2006 on batteries and accumulators and waste batteries and

accumulators and repealing Directive 91/157/EEC and legislation transposing and

implementing it into the various national legal systems.

For other countries, please contact your local government to investigate the possibility of

recycling your product.

The battery removal/replacement procedure is described in the following manuals:

Controller manual / Manipulator manual (Maintenance section)

RS Rev.16 v

Before Reading This Manual

This section describes what you should know before reading this manual.

Structure of Control System

The RS series Manipulators can be used with the following combinations of Controllers and

software.

The operating methods and descriptions are different depending on which software you are

using. The following icons are put beside appropriate text as necessary. Use the

descriptions that pertain to the software you are using.

Controller

Software

Name

Structure

RC180 Controller EPSON RC+ 5.0 Ver.5.3 or greater

RC700-A

Control Unit

Drive Unit

EPSON RC+ 7.0 Ver.7.1.2 or greater

The motions of the manipulators such as in emergency stops vary depending on the

Controllers since they have different control methods. Details are described in the

manual.

Turning ON/OFF Controller

When you see the instruction “Turn ON/OFF the Controller” in this manual, be sure to

turn ON/OFF all the hardware components. For the Controller composition, refer to the

table above.

Shape of Motors

The shape of the motors used for the Manipulator that you are using may be different from

the shape of the motors described in this manual because of the specifications.

Setting by Using Software

This manual contains setting procedures by using software. They are marked with the

following icon.

EPSON

RC+

vi RS Rev.16

TABLE OF CONTENTS

RS Rev.16 vii

Setup & Operation

1. Safety ................................................................... 3

1.1 Conventions ..............................................................................3

1.2 Design and Installation Safety ..................................................4

1.2.1 Strength of the Ball Screw Spline ...................................5

1.3 Operation Safety .......................................................................6

1.4 Emergency Stop .......................................................................8

1.4.1 RC180 .............................................................................8

1.4.2 RC700-A........................................................................10

1.5 Emergency Movement Without Drive Power .........................12

1.6 ACCELS Setting for CP Motions ............................................14

1.7 Warning Labels .......................................................................15

2. Specifications ..................................................... 18

2.1 Features of RS series Manipulators .......................................18

2.2 Model Number ........................................................................18

2.3 Part Names and Outer Dimensions ........................................19

2.3.1 RS3-351* .......................................................................19

2.3.2 RS4-551* .......................................................................23

2.4 Specifications ..........................................................................27

2.5 How to Set the Model .............................................................29

3. Environments and Installation ............................ 30

3.1 Environmental Conditions .......................................................30

3.2 Base Table ..............................................................................31

3.3 Mounting Dimensions .............................................................35

3.4 Unpacking and Transportation ...............................................36

3.5 Installation ...............................................................................37

3.5.1 Standard-model .............................................................37

3.5.2 Cleanroom-model..........................................................38

3.6 Connecting the Cables ...........................................................39

3.7 User Wires and Pneumatic Tubes ..........................................40

3.8 Relocation and Storage ..........................................................41

3.8.1 Precautions for Relocation and Storage .......................41

3.8.2 Relocation procedure ....................................................42

TABLE OF CONTENTS

viii RS Rev.16

4. Setting of End Effectors ..................................... 43

4.1 Attaching an End Effector....................................................... 43

4.2 Attaching Cameras and Air valves ......................................... 44

4.3 Weight and Inertia Settings .................................................... 44

4.3.1 Weight Setting ............................................................... 44

4.3.2 Inertia Setting ................................................................ 46

4.4 Precautions for Auto Acceleration/Deceleration of Joint #3 .. 50

5. Motion Range .................................................... 51

5.1 Motion Range Setting by Pulse Range .................................. 51

5.1.1 Max. Pulse Range of Joint #1 ....................................... 52

5.1.2 Max. Pulse Range of Joint #2 ....................................... 52

5.1.3 Max. Pulse Range of Joint #3 ....................................... 53

5.1.4 Max. Pulse Range of Joint #4 ....................................... 53

5.2 Motion Range Setting by Joint #3 Mechanical Stops ............ 54

5.3 Setting the Cartesian (Rectangular) Range in the XY Coordinate

............................... System of the Manipulator (for Joints #1 and #2)55

5.4 Standard Motion Range ......................................................... 56

Maintenance

1. Safety Maintenance ........................................... 59

2. General Maintenance ......................................... 60

2.1 Maintenance Inspection ......................................................... 60

2.1.1 Schedule for Maintenance Inspection ........................ 60

2.1.2 Inspection Point .......................................................... 61

2.2 Overhaul (Parts Replacement) ............................................... 62

2.3 Greasing ................................................................................. 64

2.4 Tightening Hexagon Socket Head Cap Bolts......................... 66

2.5 Matching Origins..................................................................... 66

2.6 Layout of Maintenance Parts ................................................. 67

3. Covers ............................................................... 68

3.1 Arm #1 .................................................................................... 69

3.1.1 Standard-model ............................................................ 70

3.1.2 Cleanroom-model ......................................................... 70

3.2 Arm #2 .................................................................................... 71

3.2.1 Arm #2 Cover ................................................................ 71

TABLE OF CONTENTS

RS Rev.16 ix

3.2.2 Under Cover ..................................................................72

3.2.3 Arm #2 Maintenance Cover ..........................................72

3.3 Connector Plate ......................................................................73

3.4 Base Cover .............................................................................74

3.5 User Plate ...............................................................................75

4. Cable Unit .......................................................... 76

4.1 Replacing Cable Unit ..............................................................77

4.2 Wiring Diagrams .....................................................................85

4.2.1 Signal Cable ..................................................................85

4.2.2 Power Cable ..................................................................87

4.2.3 User Cable ....................................................................91

4.3 Replacing M/C Cable ..............................................................92

5. Arm #1 ............................................................... 94

5.1 Replacing Joint #1 Motor ........................................................95

5.2 Replacing Joint #1 Reduction Gear Unit ................................99

5.3 Replacing J1 belt ................................................................. 102

6. Arm #2 ............................................................. 103

6.1 Replacing Joint #2 Motor ..................................................... 104

6.2 Replacing Joint #2 Reduction Gear Unit ............................. 108

6.3 Replacing J2 Belt ................................................................. 113

7. Arm #3 ............................................................. 114

7.1 Replacing Joint #3 Motor ..................................................... 115

7.2 Replacing the Timing Belt .................................................... 119

7.3 Replacing the Brake ............................................................ 120

8. Arm #4 ............................................................. 122

8.1 Replacing Joint #4 Motor ..................................................... 123

8.2 Replacing the Timing Belt .................................................... 127

8.3 Replacing the Reduction Gear Unit ..................................... 131

9. Bellows............................................................. 132

TABLE OF CONTENTS

x RS Rev.16

10. Ball Screw Spline Unit .................................... 135

10.1 Greasing the Ball Screw Spline Unit .................................. 135

10.1.1 Standard-model ........................................................ 136

10.1.2 Cleanroom-model / Protected-model ....................... 137

10.2 Replacing the Ball Screw Spline Unit ................................. 138

11. Lithium Battery ............................................... 144

11.1 Replacing the Battery Unit (Lithium Battery) ...................... 146

11.2 Replacing the Battery Board .............................................. 147

12. LED Lamp ...................................................... 148

13. Calibration ...................................................... 149

13.1 About Calibration ................................................................ 149

13.2 Calibration Procedure ......................................................... 150

13.3 Accurate Calibration of Joint #2 ......................................... 160

13.4 Calibration Procedure without using Calibration Wizard ... 162

14. Maintenance Parts List................................... 166

14.1 Common Parts .................................................................... 166

14.2 Parts by Environment Model .............................................. 168

Setup & Operation

This volume

contains information for setup and operation of the

RS

series Manipulators.

Plea

se read this volume thoroughly before setting up and

operating the Manipulators.

Setup & Operation 1. Safety

RS Rev.16 3

1. Safety

Installation and transportation of robots and robotic equipment shall be performed by

qualified personnel and should conform to all national and local codes. Please read this

manual and other related manuals before installing the robot system or before connecting

cables.

Keep this manual handy for easy access at all times.

1.1 Conventions

Important safety considerations are indicated throughout the manual by the following

symbols. Be sure to read the descriptions shown with each symbol.

WARNING

This symbol indicates that a danger of possible serious injury or

death exists if the associated instructions are not followed properly.

WARNING

This symbol indicates that a danger of possible serious injury or

death caused by electric shock exists if the associated instructions

are not followed properly.

CAUTION

This symbol indicates that a danger of possible harm to people or

physical damage to equipment and facilities exists if the associated

instructions are not followed properly.

Setup & Operation 1. Safety

4 RS Rev.16

1.2 Design and Installation Safety

Only trained personnel should design and install the robot system. Trained

personnel are defined as those who have taken robot system training and

maintenance training classes held by the manufacturer, dealer, or local

representative company, or those who understand the manuals thoroughly and

have the same knowledge and skill level as those who have completed the training

courses.

To ensure safety, a safeguard must be installed for the robot system. For details

on the safeguard, refer to the Installation and Design Precautions in the Safety

chapter of the EPSON RC+ User’s Guide.

The following items are safety precautions for design personnel:

WARNING

■

Personnel who design and/or construct the robot system with this product must

read the

Safety chapter in the EPSON RC+ User’s Guide to understand the

safety requirements before designing and/or constructing the robot system.

Designing and/or constructing the robot system without understanding the safety

requirements is extremely hazardous, may result in serious bodily injury and/or

sever

e equipment damage to the robot system, and may cause serious safety

problems.

■

The Manipulator and the Controller must be used within the environmental

conditions described in their respective manuals.

This product has been

designed and manufactured strictly for use in a normal indoor

environment. Using

the product in an environment that exceeds the specified environmental

conditions may not only shorten the life cycle of the product but may also cause

serious safety problems.

■

The robot system must be used within the installation requirements described in

the manuals.

Using the robot system outside of the installation requirements

may not only shorten the life cycle of the product but also cause serious safety

problems.

Further precautions for installation are mentioned in the chapter Setup &

Operation: 3. Environments and Installation. Please read this chapter carefully to

understand safe installation procedures before installing the robots and robotic

equipment.

Setup & Operation 1. Safety

RS Rev.16 5

1.2.1 Strength of the Ball Screw Spline

If a load exceeding the allowable value is applied to the ball screw spline, it may not work

properly due to deformation or breakage of the shaft. If the ball screw spline is applied

the load exceeding the allowable value, it is necessary to replace the ball screw spline unit.

The allowable loads differ depending on distance where the load is applied to. For

calculating the allowable load, see the calculation formula below.

[Allowable bending moment]

RS3/RS4: M=13,000 N

∙

mm

Example: If 130 N load is applied

at 100 mm from

the end of the spline nut

[Moment]

M=F

∙

L

＝

100

∙

130

＝

13,000 N

∙

mm

End of the

spline nut

F

L

Setup & Operation 1. Safety

6 RS Rev.16

1.3 Operation Safety

The following items are safety precautions for qualified Operator personnel:

WARNING

■

Please carefully read the

Safety-related Requirements in the Safety chapter of

the

Safety and Installation manual before operating the robot system. Operating

the robot system without understanding the safety requirements is extremely

hazardous and may result in serious bodily injury and/or sever

e equipment

damage to the robot system.

■

Do not enter the operating area of the Manipulator while the power to the robot

system is turned ON.

Entering the operating area with the power ON is

extremely hazardous and may cause serious safety problems as the Manipulator

may move even if it seems to

be stopped.

■

Before operating the robot system, make sure that no one is inside the

safeguarded area.

The robot system can be operated in the mode for teaching

even when someone is inside the safeguarded area.

The motion of the Manipulator is always i

n restricted (low speeds and low power)

status to secure the safety of an operator.

However, operating the robot system

while someone is inside the safeguarded area is extremely hazardous and may

result in serious safety problems in case that the Manipulator moves

unexpectedly.

■

Immediately press the Emergency Stop switch whenever the Manipul

ator moves

abnormally while the robot system is operated.

WARNING

■

To shut off power

to the robot system, disconnect the power plug from the power

source. Be sure to connect the AC power cable to a power receptacle.

DO NOT connect it directly to a factory power source.

■

Before

performing any replacement procedure, turn OFF the Controller and

related equipment,

and then disconnect the power plug from the power source.

Performing any replacement procedure with the power ON is extremely

hazardous and may result in

electric shock and/or malfunction of the robot

system.

■

Do not

connect or disconnect the motor connectors while the power to the robot

system is turned ON.

Connecting or disconnecting the motor connectors with

the power ON is extremely hazardous and may result

in serious bodily injury as

the Manipulator may move abnormally, and also may result in

electric shock

and/or malfunction of the robot system.

Setup & Operation 1. Safety

RS Rev.16 7

CAUTION

■

Whenever possible, only one person should operate the robot system.

If it is

necessary to operate the robot system with more than one person, ensure that all

people involved communicate with each other as to what they are doing and take

all necessary safety precautions.

■

Joint #1, #2, and #4:

If the joints are operated

repeatedly with the operating angle less than 5 degrees,

they may get damaged early because the bearings are likely to cause oil film

shortage in such situation. To prevent early breakdown, move the joints larger

than 50 degrees

for about five to ten times a day.

Joint #3:

If the up

-and-down motion of the hand is less than 10 mm, move the joint a half of

the maximum stroke for five to ten times a day.

■

Oscillation (resonance) may

occur continuously in low speed Manipulator motion

(Speed:

approx. 5 to 20%) depending on combination of Arm orientation and end

effector load. Oscillation arises from natural oscillation frequency of the Arm

and can be controlled by following measures.

Changing Manipulator speed

Changing the teach points

Changing the end effector load

Setup & Operation 1. Safety

8 RS Rev.16

1.4 Emergency Stop

Emergency stop motions of the Manipulators vary due to difference of control methods of

the Controllers. See the section for your Controller model.

1.4.1 RC180

If the Manipulator moves abnormally during operation, immediately press the Emergency

Stop switch. Stops the power supply to the motor, and the arm stops in the shortest

distance with the dynamic brake and mechanical brake.

However, avoid pressing the Emergency Stop switch unnecessarily while the Manipulator

is running normally. Otherwise, the Manipulator may hit the peripheral equipment since

the operating trajectory while the robot system stops is different from that in normal

operation. It may also result in short life of the reduction gear unit due to the shock or

the electromagnetic brake due to the worn friction plate.

To place the system in emergency mode during normal operation, press the Emergency

Stop switch when the Manipulator is not moving.

Refer to the Controller manual for instructions on how to wire the Emergency Stop switch

circuit.

Do not press the Emergency Stop switch unnecessarily while the Manipulator is operating.

Pressing the switch during the operation makes the brakes work. This will shorten the

life of the brakes due to the worn friction plates.

Normal brake life cycle: About 2 years (when the brakes are used 100 times/day)

Do not turn OFF the Controller while the Manipulator is operating.

If you attempt to stop the Manipulator in emergency situations such as “Safeguard Open”,

make sure to stop the Manipulator using the Emergency Stop switch of the Controller.

If the Manipulator is stopped by turning OFF the Controller while it is operating,

following problems may occur.

Reduction of the life and damage of the reduction gear unit

Position gap at the joints

In addition, if the Controller was forced to be turned OFF by blackouts and the like while

the Manipulator is operating, make sure to check the following points after power

restoration.

Whether or not the reduction gear is damaged

Whether or not the joints are in their proper positions

If there is a position gap, perform calibration by referring to the Maintenance 13.

Calibration in this manual.

Before using the Emergency Stop switch, be aware of the followings.

- The Emergency Stop (E-STOP) switch should be used to stop the Manipulator only

in case of emergencies.

- To stop the Manipulator operating the program except in emergency, use Pause (halt)

or STOP (program stop) commands.

Pause and STOP commands do not turn OFF the motors. Therefore, the brake does

not function.

- For the Safeguard system, do not use the circuit for E-STOP.

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